Control of Hazardous Energy (Lockout/Tagout) 29 CFR

Objectives In this course, we will cover the following:  The need for energy control procedures  Methods of lockout/tagout  Employer’s responsibilities  Employee training needs  Inspection requirements

Lockout/Tagout Technically known as the Control of Hazardous Energy  Control of unexpected energization or start-up of machines or equipment, or release of stored energy that could cause injury to employees

Scope Covers the servicing and/or maintenance of machines or equipment where the unexpected start-up or release of stored energy could cause injury  Installation and set-up  Adjustment or maintenance  Inspection  Modification  Routine service (a)(1)

Scope Does not cover  Construction, agriculture, maritime  Installations under exclusive control of the electric utilities for power generation, transmission and distribution  Exposure to electrical hazards from work on, near, or with conductors or equipment in electric-utilization installations  Oil and gas drilling and servicing (a)(1)

Servicing and/or maintenance which takes place during normal production operations is covered only if:  Employee is required to remove or bypass a guard or other safety device; or  Employee is required to place any part of his/her body into the point of operation or where an associated danger zone exists during a machine operation. Application (a)(2)

Exception  Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered if they are:  Routine,  Repetitive, and  Integral to the use of the equipment for production provided that the work is performed using alternative measures which provide effective protection Application (a)(2)

Application Does not cover:  Normal production operations  Work on cord and plug connected equipment where plug is under exclusive control of employee performing servicing/maintenance  Hot tap operations, under special conditions (a)(2)

Authorized employee  An employee who locks out or tags out machines or equipment to perform servicing or maintenance on that machine or equipment  Lockout or tagout is used by these employees for their own protection Definitions (b)

Definitions Affected employee  An employee who performs the duties of his or her job on equipment or in an area in which the energy control procedure is implemented and servicing or maintenance operations are performed (b)

Other employees  Other employees whose work operations are, or may be, in an area where energy control procedures may be utilized Other Employees (c)(7)

Energy source  Mechanical  Hydraulic  Chemical  Pneumatic  Electrical  Thermal Definitions (b)

Energy Control Program The employer shall establish a program consisting of:  Energy control procedures  Employee training  Periodic inspections (c)(1)

Energy Control Program If an energy isolating device is not capable of being locked out, the employer’s energy control program shall utilize a “tagout system” (c)(2)

Energy Control Program When a tagout device is used on an energy isolating device which is capable of being locked out  Tagout device shall be attached at the same location  Must provide equivalent safety (c)(3)

Energy Control Procedure Procedures  Shall be developed, documented and utilized for the control of potentially hazardous energy  Shall clearly and specifically outline techniques to be utilized to control hazardous energy (c)(4)

Energy Control Procedure Energy control (LOTO) procedure  Statement of intended use of procedure  Steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy  Steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them, and  Requirements for testing machine/equipment to determine and verify effectiveness of LOTO devices and other energy control measures (c)(4)

Procedure Exception Machine/equipment has no potential for stored/residual energy after shut down Machine/equipment has a single energy source (readily identified and isolated The isolation and locking out of energy source will completely de-energize/deactivate the machine/equipment Machine/equipment is isolated from that energy source and locked out during servicing or maintenance (c)(4)

Procedure Exception (c)(4) Lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance Servicing/maintenance does not create hazards for other employees; and Employer has had no accidents involving the unexpected activation/re-energization of the machine/equipment during servicing/maintenance

Materials and Hardware Provided by employer Singularly identified Only device(s) used Not used for other purposes (c)(5)

Materials and Hardware Durable Standardized Substantial Identifiable (c)(5)

Types of Devices

Is this lockout identifiable? (c)(5)

Is this lockout identifiable? Based on the photo, it is not (c)(5)

Periodic Inspection Conducted at least annually to ensure procedure and requirements are followed Performed by authorized employee other than the one(s) using the procedure Designed to correct identified deficiencies or inadequacies Employer shall certify that periodic inspection has been performed (c)(6)

Periodic Inspection Lockout inspection  Must review each authorized employee’s responsibilities under the energy control procedure Tagout inspection  Must review each authorized and affected employee’s responsibilities under the energy control procedure, and  Additional training requirements of (c)(7)(ii) (c)(6)

Training and Communication Authorized employee  Recognition of hazardous energy sources  Type and magnitude of energy in workplace  Methods and means for energy isolation and control Affected employee  Purpose and use of the energy control procedure (c)(7)

All other employees  Procedures for energy control  Prohibition of restarting or reenergizing machines that are locked or tagged out (c)(7) Training and Communication

Tagout system limitations  Warning devices only; do not provide physical restraint  Must not be removed/bypassed/ignored  Must be legible and understandable  Must withstand environmental conditions  May evoke false sense of security  Must be securely attached (c)(7) Training and Communication

Retraining for authorized and affected employees  Change in job assignments  Change in machines, equipment or processes that present new hazards  Change in energy control procedures  Whenever periodic inspections reveal, or employer has reason to believe, there are deviations in employee knowledge or use of procedures (c)(7) Training and Communication

Is this a proper lockout?

No Why?

Energy Isolation Lockout or tagout shall be performed only by the authorized employees who are performing the servicing or maintenance (c)(8)

Notification of Employees Affected employees shall be notified by the employer or authorized employee of the application and removal of LOTO devices Notification given before controls are applied, and after they are removed from the machine or equipment (c)(9)

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Preparation for Shutdown Know the types and amounts of energy Know the hazards of the energy Know method or means to control energy (d)(1) Mechanical ? Hydraulic ? Chemical ? Pneumatic ? Electrical ? Thermal ?

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Machine/Equipment Shutdown Turn off or shut down using established procedures Utilize orderly shutdown to avoid additional or increased hazard(s) to employees as a result of the equipment stoppage (d)(2)

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Machine/Equipment Isolation All energy isolating devices needed to control energy shall be physically located to isolate the machine or equipment from the energy source(s) (d)(3)

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Lockout/Tagout Application Devices shall be affixed to each energy isolating device by authorized employees Lockout devices shall be affixed in a manner that will hold the energy isolating devices in a “safe” or “off” position Tagout devices shall be affixed in a manner indicating that the operation or movement of energy isolating devices from the “safe” or “off” position is prohibited (d)(4)

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Release of Stored Energy After application of device, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe (d)(5)

Control Sequence Application of control 1.Preparation for shutdown 2.Machine or equipment shutdown 3.Machine or equipment isolation 4.LOTO device application 5.Release of stored energy 6.Verification of isolation (d)

Verification of Isolation Prior to starting work on machines or equipment that have been locked out/tagged out  Authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished (d)(6)

Control Sequence Release from LOTO 1.Inspection of machine or equipment work area 2.Location of employees 3.LOTO device removal (e)

Control Sequence (e) Release from LOTO 1.Inspection of machine or equipment work area 2.Location of employees 3.LOTO device removal

Inspection of Work Area Before LOTO devices are removed and energy restored  Work area inspected to ensure that nonessential items have been removed and to ensure that machine or equipment components are operationally intact (e)

Control Sequence (e) Release from LOTO 1.Inspection of machine or equipment work area 2.Location of employees 3.LOTO device removal

Location of Employees Before LOTO devices are removed and energy restored  Work area shall be checked to ensure that all employees have been safely positioned or removed  Affected employees notified that LOTO devices are removed (e)

Control Sequence (e) Release from LOTO 1.Inspection of machine or equipment work area 2.Location of employees 3.LOTO device removal

LOTO Device Removal Each LOTO device shall be removed from each energy isolating device by the employee who applied the device  Exception: When authorized employee who applied the LOTO device is not available, device may be removed under the direction of the employer (e)(3)

LOTO Device Removal Employer removal of LOTO device  Specific procedure shall include: »Verification by employer that authorized employee who applied device is not at the facility »Making all reasonable efforts to contact authorized employee to inform them that LOTO device has been removed, and »Ensuring that authorized employee has this knowledge before they resume work at facility (e)(3)

Testing/Positioning Machines When LOTO devices must temporarily be removed for testing/positioning:  Clear machine or equipment of tools and materials  Remove employees from area  Remove lockout/tagout device  Energize and proceed with testing or positioning  Deenergize and reapply energy control measures (f)

Outside Personnel Contractors and the on-site employer must exchange lockout/tagout information On-site employees must understand and comply with rules used by the contractor (f)(2)

Group Lockout/Tagout When servicing and/or maintenance is performed by a group, they shall utilize a procedure which affords employee protection equivalent to a personal LOTO device (f)(3)

Group Lockout/Tagout Primary responsibility is vested in an authorized employee Authorized employee must ascertain exposure status of group members If more than one crew is involved, a coordinator shall be designated Each authorized employee shall use a personal LOTO device and remove device when they stop working on machine/equipment (f)(3)

Shift/Personnel Changes Specific procedures used during shift/personnel changes to ensure the continuity of LOTO protection  To minimize exposures from the unexpected energization or start- up of the machine/ equipment, or release of stored energy (f)(4)

Sample LOTO Program Typical minimal lockout procedures  A non-mandatory guideline to assist employers and employees in complying with the requirements of this section Appendix A

Summary ● In this course, we discussed:  The need for energy control procedures  Methods of lockout/tagout procedures  Employer’s responsibilities  Employee training needs  Inspection requirements

Thank You For Attending! Final Questions?